U.S. patent number 3,768,720 [Application Number 05/199,916] was granted by the patent office on 1973-10-30 for flat foldable carton having a supported intermediate tray.
Invention is credited to Patrick L. Bundy.
United States Patent |
3,768,720 |
Bundy |
October 30, 1973 |
FLAT FOLDABLE CARTON HAVING A SUPPORTED INTERMEDIATE TRAY
Abstract
A carton is provided which may be prepared from an integral
blank and which when properly glued together, may be stored in flat
folded condition. The folded carton may be quickly erected to form
a carton in the form of a polygonal prism having a closed bottom
and another end which is readily closable by interlocking a
plurality of flaps. A separate tray is provided which is inserted
into the carton at an intermediate position. The side walls of the
carton are suitably cut and scored to provide tabs which, upon
erection of the carton, are punched inwardly to provide vertically
oriented supports for the tray.
Inventors: |
Bundy; Patrick L. (Battle
Creek, MI) |
Family
ID: |
26733725 |
Appl.
No.: |
05/199,916 |
Filed: |
November 18, 1971 |
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
54997 |
Jul 15, 1970 |
3700161 |
Oct 16, 1972 |
|
|
Current U.S.
Class: |
229/117.25;
229/117.24; 229/117.26; 229/120.32; 229/155; 229/183; 229/117.19;
229/120; 229/138; 229/156; 229/184 |
Current CPC
Class: |
B65D
5/48024 (20130101); B65D 5/06 (20130101) |
Current International
Class: |
B65D
5/02 (20060101); B65D 5/49 (20060101); B65D
5/06 (20060101); B65D 5/48 (20060101); B65d
005/36 (); B65d 005/46 () |
Field of
Search: |
;229/39,41C,41B,52AL,52AW,15,42 ;217/26.5 ;206/45.31 ;248/174 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Moorhead; Davis T.
Parent Case Text
This application is a continuation-in-part of pending application
Ser. No. 54,997, filed July 15, 1970, for A FLAT FOLDABLE CARTON
HAVING A PREFORMED ANCHORED IN PLACE, AND FOLDED BOTTOM, WITH
SELF-LOCKING TOP, by the present inventor, now U.S. Pat. No.
3,700,161, issued Oct. 24, 1972.
Claims
I claim:
1. A carton in the form of a polygonal prism comprising:
a. a plurality of side panels,
b. a top closure,
c. a bottom closure,
d. a tray positioned intermediate said top closure and said bottom
closure, and
e. support means associated with said side panels engaging and
supporting said tray, wherein some of said side panels are
appropriately cut and formed to provide a plurality of planar tabs
extending inwardly and in a vertical plane with respect to said
carton, said tabs engaging and supporting said tray at their
edges.
2. A carton according to claim 1, having at least six sides.
3. A carton according to claim 1, which is hexagonal.
4. A carton according to claim 1, wherein said tabs have arcuate
ends.
5. A carton according to claim 1, wherein said tray is provided
with vertically extending flaps frictionally engaging the side
panels of said carton.
6. A carton according to claim 1, wherein said top closure
comprises a plurality of closure flaps hingedly connected to the
ends of said side panels and interconnected laterally to form a
closed loop, each of said closure flaps comprising a flap member
and a triangular web hingedly connected thereto, said flap members
and said webs each having an edge perpendicular to the hinge line
connecting said flap members and said side panels and another edge
oblique thereto, the oblique edges of said flap members and said
webs being hingedly connected together, and the perpendicular edges
of said flap members and triangular webs being connected to the
perpendicular edges of webs and flap members, respectively, of
adjacent closure flaps, the oblique edges of said flap members
passing through the center of said closure when said flap members
are in closed condition, said flap members terminating in an
arcuate tab extending beyond the center of said closure.
7. A carton according to claim 6, wherein said bottom closure
comprises:
a. a polygonal bottom panel being connected at one edge to the end
of one of said side panels and having substantially the same
dimensions and shape as the cross-section of said carton, and
b. two supporting flap assemblies disposed one on each side of and
below said polygonal bottom panel, each of said assemblies
comprising:
1. a first supporting flap hingedly connected to the end of one of
said side panels,
2. a second supporting flap hingedly connected to the end of an
adjacent one of said side panels comprising a supporting flap
member and a glue flap member hingedly connected thereto, and
3. said glue flap being adhesively affixed to a medial portion of
said first supporting flap and said first supporting flap having an
overhanging portion extending beyond the hinge line between said
supporting member and said glue member,
the arrangement being such that each supporting flap assembly folds
inwardly at the hinge line between said hinge member and said flap
member permitting said bottom closure to be folded flat with the
remainder of said carton for storage, and whereby when said carton
is erected and said bottom closure is placed in planar position
said overhang abuts the upper surface of said supporting flap
member, thereby restraining said flap assembly from bending
outwardly of said carton, and providing positive support for said
polygonal flap.
8. A carton according to claim 1, wherein a pair of apertures are
provided in the side panels, a handle the ends of which pass
through said apertures, and means anchoring the ends of said handle
within said carton.
Description
BACKGROUND OF THE INVENTION
The invention deals broadly with foldable boxes or cartons, and
more particularly refers to such cartons which may be erected into
polygonal and preferably hexagonal prism form having one closed end
and another which is readily closed and locked.
Polygonal and particularly hexagonal cartons have been disclosed in
the art, but because of their form, they are generally not able to
be folded flat for storage. However, even where collapsible
hexagonal cartons have been provided, the strength and rigidity
particularly of the bottom end are not sufficient for containing
such articles as parts of fried chicken. Such items are generally
placed in bucket-type paper cartons which are not foldable, and
therefore require a considerable amount of storage space.
Additionally, prior art cartons of prismatic form generally have
only a single compartment. Consequently, when two different food
items are to be packaged together in the carton, as for example
fried fish and french-fried potatoes, the excess grease of one food
item such as fish may drain onto the other food item such as
french-fried potatoes, and thereby render them exceedingly and
undesirably soggy.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a
carton which can be glued and erected in the shape of a polygonal
and preferably hexagonal prismatic form.
It is a primary object of the invention to provide a carton of the
type described having an intermediately disposed tray and means for
supporting the tray, in order to permit two different items to be
separately packaged within the carton.
It is another object of the invention to provide a bottom for the
carton which, although it may be folded flat for storage, it can be
readily set up to provide a strong, full bottom which additionally
aids in retaining the polygonal shape of the carton.
It is still further an object to provide a carton having such a
bottom which will contain even small items without danger of
loss.
It is still further an object to provide a hexagonal carton having
improved closing and locking means.
It is an additional object to provide a carton of the type
described which can be formed of an integral blank suitably cut and
scored.
Still further objects and advantages of the invention will appear
as the description proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
To the accomplishment of the foregoing and related ends, the
invention, then, consists of the carton herein fully described and
particularly pointed out in the claims, the annexed drawings and
the following description setting forth in detail certain
illustrative embodiments of the invention, such disclosed
embodiments illustrating, however, but several of the various ways
in which the principle of the invention may be used.
In the annexed drawings:
FIG. 1 is a perspective view of a fully erected and closed carton
according to the invention illustrating the top closure.
FIG. 2 is a perspective view of the carton of FIG. 1 illustrating
the bottom closure.
FIG. 3 is a plan view of an integral blank which may be utilized to
form a carton such as shown in FIGS. 1 and 2.
FIG. 4 is a plan view of a carton which has been glued together but
which is folded flat in storage condition.
FIG. 5 is an end view taken at the line V--V of FIG. 4, looking in
the direction of the arrows.
FIG. 6 is a top view of the carton of FIGS. 1-5 which has been
glued, the bottom folded in place, and the top flaps open for
filling the carton.
FIG. 7 is a top view of the carton of FIG. 6 in which the flaps are
in partially closed condition.
FIG. 8 is a top view showing the carton of FIGS. 6 and 7 with the
top completely closed and the flaps interlocked.
FIG. 9 is a side elevational view showing the top not completely
closed.
FIG. 10 is a fragmentary elevational view showing the top
completely closed.
FIG. 11 is a cross-sectional view taken at line XI--XI of FIG. 10,
looking in the direction of the arrows.
FIG. 12 is a bottom view of the carton of the invention.
FIG. 13 is a sectional view taken at the line XIII--XIII of FIG.
12, looking in the direction of the arrows.
FIG. 14 is a sectional view taken at the line XIV--XIV of FIG. 13,
looking in the direction of the arrows.
FIG. 15 is a plan view of a blank for forming a tray.
FIG. 16 is a perspective view of the tray of FIG. 15 with the edges
folded and ready for insertion into the carton.
FIG. 17 is a cross-sectional view taken at the line XVII--XVII of
FIG. 1, looking in the direction of the arrows.
FIG. 18 is an axial cross-sectional view taken at the line
XVIII--XVIII of FIG. 11, looking in the direction of the arrows,
illustrating the tray supported by the support tabs; and
FIG. 19 is a plan view of a handle.
DESCRIPTION OF THE SPECIFIC EMBODIMENTS
Referring more particularly to FIGS. 1 and 2, the carton 10 is
shown in perspective having a top closure 33 and a bottom closure
34. FIG. 3 illustrates an integral blank 11 from which the carton
may be constructed and in which the various panels may be more
clearly distinguished. The carton comprises side panels 12, 13, 14,
15, 16 and 17, and a glue flap 18 and 18a for affixing the edge of
the panel 17 to the edge of the panel 12 by means of an adhesive 19
such as glue applied to the edge of the panel 12 and flap 20. The
top closure is comprised of a plurality of top flaps 20, 21, 22,
23, 24 and 25 affixed to the ends of the side panels at hinge lines
26, 27, 28, 29, 30 and 31, respectively. The top flaps are
connected together by triangular webs 36, 37, 38, 39, 40 and 41 at
hinge lines 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52 and 32. Each
of the top flaps 20-25 have one lateral edge (35, 43, 45, 47, 49
and 51) perpendicular to the respective fold lines 26-31 of the
flaps. Additionally, each flap 20-25 has one lateral edge (42, 44,
46, 48, 50 and 52) oblique with respect to the fold lines 26-31 of
the flaps. In similar manner, each of the triangular webs 36-41 has
a lateral edge (43, 45, 47, 49, 51 and 32) perpendicular to the
fold lines 26-31, and another lateral edge (42, 44, 46, 48, 50 and
52) oblique to the fold lines. This arrangement permits the flaps
20-25 to be positioned either co-planar with the lateral panels
12-17 to present an open end of the carton, or alternatively
perpendicular to the panels and cooperating with the triangular
webs to form the interlocking pattern shown in FIG. 1. Each of the
flaps 20-25 are provided at their ends with semi-circular tabs 53,
54, 55, 56, 57 and 58.
The bottom closure, FIG. 3, comprises a hexagonal flap 65 having a
tab 64 at its end, and a pair of supporting flap assemblies. One
supporting flap assembly 66 comprises a supporting flap member 67
and a triangular glue flap member 68 connected thereto at a hinge
line 69. An end supporting flap 70 is hingedly connected to the
side panel 14. At the other side of the hexagonal flap 65 is
another flap assembly 75 comprising a supporting flap member 76 and
a triangular glue flap member 77 connected thereto at a hinge line
78. The flap members 67 and 76 are provided with arcuate or rounded
edges to prevent entanglement with other flaps or panels. An end
supporting flap 79 is hingedly connected to the side panel 16. The
end supporting flaps 70 and 79 are provided with recesses 85 and
86, respectively, to provide clearance of the hexagonal flap 65.
Ventilation holes 60, 61 and 62 may be provided in the carton top
if desired.
In gluing the carton together, the hexagonal flap 65 is first
folded over against the side panels 14, 15 and 16. The flap
assembly 75 and end supporting flap 79 are then folded over against
the side panels 16 and 17. The triangular glue flap member 77 is
then folded back against the flap 76 and glue placed on the exposed
surface of the triangular glue flap 77. The side panel 17 is then
folded over against the side panel 16. The triangular glue flap 77
is thereby adhesively affixed to a medial portion of the end
supporting flap 79 but leaving an overhang 79a, FIG. 14, of the
flap 79 beyond the glue flap supporting member 77. The flap
assembly 66 and end flap 70 are then folded over against the side
panels 13 and 14. The triangular glue flap member 68 is then folded
back against the flap 67 and glue applied. The panel 13 is then
folded over against the panel 14, causing the triangular glue flap
member 68 to be adhesively affixed to a medial portion of the end
flap 70 but leaving an overhang 70a, FIG. 14. Glue 19 is then
applied to the edge of the side panel 12 and end panel 20 which are
then caused to be affixed to the glue strip 18 and 18a, the carton
then being of the form shown in FIGS. 4 and 5, and in which
condition the carton may be stored and transported.
According to the invention, a tray 90 is formed from an integral
blank suitably cut and scored to provide a main panel 91, and
corner flaps 92, 93, 94 and 95 hingedly connected to the main panel
91 at score lines 96, 97, 98 and 99, respectively. Lateral flaps
100 and 101 are hingedly connected to the main panel 91 by means of
score lines 102 and 103. In order to provide a supporting structure
for the tray 90, side panels 13, 14, 16 and 17 are suitably cut to
provide support tabs 106, 107, 108 and 109 (FIGS. 1-4), which when
punched inwardly during assembly of the carton, assume vertically
and inwardly oriented positions, serving to support the tray 90, as
shown in FIG. 18. In the embodiment shown four tabs are utilized
which are symmetrically distributed. This configuration results in
a strong supporting means for the tray 90. Additionally, the
positioning of each pair of tabs on adjacent side panels permits
the tabs to be punched in easily by the thumb and forefinger of
each hand when the carton is being set up. Alternatively three tabs
or more than four could be utilized. A pair of apertures 112 and
113 are provided for anchoring the ends of a plastic handle 114
having transverse lugs 115 which form an integral part of the
handle (FIGS. 1 and 19) which engage the inner surfaces of the
carton. The ends of the handle 114 are inserted into the apertures
112 and 113, with the lugs 115 completely within the carton.
The carton is erected by compressing together the opposite side
edges, thereby opening the carton, and then pushing the hexagonal
flap 65 outwardly until it engages the glued together flaps 67 and
70, and 76 and 79, which flaps retain the hexagonal flap 65 in
position. The tab 64 is at the same time bent until its flap
surface engages the panel 12, thereby forming a substantially
leakproof container, as shown in FIGS. 12, 13 and 14. In this
condition the overhanging areas 70a and 79a reinforce the bottom
and prevent outward bending of the flap at the hinge lines 69 and
78 (FIGS. 12, 13 and 14).
The tray 90 is prepared for insertion into the carton by turning up
the flaps 92, 93, 94 and 95 and the lateral flaps 100 and 101, as
shown in FIG. 16. The contents to be inserted into the lower
portion of the carton, as for example fried fish or chicken, are
placed therein. The support tabs 106, 107, 108 and 109 are then
punched inwardly to provide a support for the tray. The tray 90 is
then inserted into the carton with the flaps extended upwardly, and
pushed downwardly until it engages the support flaps. The remaining
contents, as for example french-fried potatoes, are then placed
into the carton above the tray.
After the desired contents have been placed in the carton, the
carton is closed by first forming a star pattern such as shown in
FIG. 7, and pinching toward the center, as shown in FIGS. 7 and 9.
When the flaps reach the flattened position as shown in FIGS. 8, 10
and 11, the flaps are interlocked and the top remains closed. The
top may be opened by raising and disengaging the flaps.
The carton of the present invention has many advantages over prior
art cartons. The primary advantage is that it permits two different
products to be packaged within the carton but maintained in
separated state so that there is no intermixing. This is
particularly advantageous when a food item such as fried fish or
fried chicken is to be packaged together with another food item
such as french-fried potatoes. The presence of a tray maintains the
two different food items in separated condition, and prevents
excess grease from the food items such as fried fish or fried
chicken from mixing with the french-fried potatoes, a condition
which generally causes the potatoes to become overly soggy. The
tray structure is quite simple to assemble and insert, and in
cooperation with the easily set-up support tabs, forms a very
strong separating structure.
Other features of the carton are additionally advantageous. Because
of the arrangement of the bottom flaps which are glued together and
which sustain the hexagonal flap, an exceedingly strong supporting
bottom structure is formed. The closure structure is further
strengthened by the presence of the supporting flap overhangs which
prevent the flaps from bowing outward at the glue flap hinge lines.
Moreover, the bottom flaps are so arranged that they may be folded
for storage. Additionally, because of the unique pattern of the
flaps and because of the way in which they fold, the entire carton
may be readily folded flat for storage and transportation, and
subsequently quickly erected. The unique arrangement of the top
flaps provides a positive locking and attractively appearing
top.
While but one embodiment of the invention has been illustrated and
described herein, it is to be understood that minor modifications
may be made to the carton, as well as the construction and
arrangement of its bottom flaps within the spirit and scope of the
invention, as herein set forth. It is also to be noted that while
directional terms have been used, same are not to be construed as a
limitation of the invention since such use has been availed of to
better describe the invention in the position illustrated in the
drawings.
* * * * *